Contents

Executive Summary

The DeWalt 4 ½ in Angle Grinder is a heavy duty angle grinder designed primarily for professional use. By attaching a variety of different discs the product is able to perform a wide array of functions including, but not limited to, grinding, polishing, sanding, and cutting. Our group dissected and analyzed the components of this product in order to not only determine how it performs these functions, but also to find ways to improve it.

The dissection our group performed allowed our group to analyze the subsystems, components, and their connections. The angle grinder delivers a high RPM torque to its disc by in-taking electricity through its power cord, delivering this electricity to the electromagnet and armature when the switch (controlled by user) was in the “ON” position, and then connecting the armature to a pinion and helical gear in order to deliver the mechanical energy to the disc. There were also many auxiliary parts that facilitated this overall process (i.e. a fan baffle). The complete analysis of all components can be found in Gate 3.

Lastly, our group reassembled the product and we now propose a total of six design revisions to the DeWalt Angle Grinder. These revisions vary in scope and complexity from replacing simple components to system-level revisions. Overall these revisions aim to enhance the functionality and versatility of the angle grinder, and by extension increase sales and profitability. The simple component level revisions our group proposes can be found in Gate 3. The more complex system level revisions can be found in Gate 4.

Overall this project was a success as the gates our group has created contain a very thorough and in-depth analysis of this product. With this information in hand, we created several revision proposals that will allow DeWalt to improve this product and satisfy consumer demands in the future.

Group Members

Ethan George

Michael Halloran

Zachary Picciano

Thakur Phuyel

Tharaka Gabadage

Gate 1

In Gate 1 our group formed a plan for dissecting the product, assigned roles and responsibilities to each group member, and came up with a general idea of what we expected to find when dissecting our product.

Gate 2

In Gate 2 our group assessed how we were performing and what issues needed to be fixed within our current group structure. We then dissected our product and formed step by step instructions for this dissection process, along with an analysis of why the subsystems were arranged the way they were.

Gate 3

In Gate 3 our group did an analysis of the manufacturing methods of all parts, along with an in depth analysis of several of the key components of our system. We also considered how engineering analysis would be used in the design of our component's motor. Lastly, our group considered how our changes to group structure have worked and what other issues still need to be addressed.

Gate 4

In Gate 4 our group reassembled our product and created step-by-step instructions for putting the product back together. We also considered how the methods we used for reassembly compared to the disassembly, as well as the original assembly methods that would have been used in a factory. Lastly, our group assessed the effectiveness of our solutions to any outstanding problems within the group structure.